Solid electrolytic capacitor and method for manufacturing the same

ABSTRACT

In the present invention, a capacitor element including a valve action metal an oxide film layer formed on the surface of the valve action metal, and a solid electrolytic layer formed on the oxide film layer is provided with an organic compound having a boiling point of not lower than 150° C. and a melting point of not higher than 150° C., and the capacitor element including the organic compound is arranged inside a package. The oxide film is repaired with the organic compound as a solvent by an application of a dc voltage.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a solid electrolytic capacitorincluding an anode made of a valve action metal such as aluminum,tantalum or niobium, and also including a solid electrolyte such as aconductive polymer or manganese dioxide. The present invention alsorelates to a method for manufacturing the solid electrolytic capacitor.

[0003] 2. Description of the Prior Art

[0004] A typical solid electrolytic capacitor including a valve actionmetal for an anode is manufactured in the following manner. First, ananode is made of a porous compact of the valve action metal such as asurface-roughened aluminum foil or a porous compact of a sintered powderof a valve action metal such as tantalum or niobium. The entire surfaceof the porous compact of the valve action metal is covered with adielectric oxide film. Secondly, a solid electrolytic layer of aconductive polymer such as polypyrrole or manganese dioxide is formed onthe surface of the dielectric oxide film, and a cathodic layer of acarbon layer, a silver layer or the like is formed on the solidelectrolytic layer. Subsequently, an anodic extraction terminal isattached to an anodic lead by welding or the like, and a cathodicextraction terminal is attached to a cathodic layer with a conductiveadhesive or the like. Lastly, the entire element is covered with apackaging resin from which the cathodic extraction terminal and theanodic extraction terminal are partially exposed to the outside.Alternatively, the solid electrolytic layer can be connectedelectrically with the cathodic extraction terminal without forming acathodic layer.

[0005] Since the packaging resin serves to maintain airtightness fromthe outside, it should be adhered securely to electrode extractionmembers such as a lead, a foil and a terminal. Especially, when thesolid electrolyte is a conductive polymer, insufficient airtightnesswill cause considerable deterioration. And thus, the electric propertieswill be difficult to maintain favorably for a long time. Therefore, forsecuring the airtightness, the packaging resin is formed generally froman epoxy-based thermosetting resin, using molding (a tip capacitor) ordipping (a lead capacitor).

[0006] A solid electrolytic capacitor having a case instead of apackaging resin is also known. Such a capacitor is manufactured byinserting an entire element in a case where a cathodic extractionterminal and an anodic extraction terminal are partially extractedoutward, and by sealing the opening of the case with a resin or thelike. The case is an insulator such as a resin or ceramic, or a metalhaving an insulated portion for a connection with terminal parts.

[0007] Generally, an electrolytic capacitor including an electrolyticsolution can repair defects on a dielectric oxide film caused during amanufacturing process. Therefore, leakage current will not be increasedconsiderably. However, a solid electrolytic capacitor including a solidelectrolyte does not have sufficient capability to repair the dielectricoxide film. Such a dielectric oxide film cannot self-repair defectsthereon. When the dielectric oxide film deteriorates due to stresses inmanufacturing, such as mechanical stress and thermal stress, the leakagecurrent tends to increase.

[0008] Conventionally, solid electrolytic capacitors are aged todecrease leakage current by applying a predetermined dc voltage to aninterface between the anodic and cathodic terminals before or afterformation of the package. In an aging, a film is repaired using waterthat has been absorbed from the atmosphere as an electrolytic solution.However, since this repair depends on moisture absorption, aconventional aging requires a long period to provide a stable leakagecurrent property.

[0009] JP-A-5-243096 discloses a method to insulate a conductive polymerused for a solid electrolyte with Joule heat by concentrating a currenton a part with lowered voltage resistance. However, when the defect islarge, the insulation may be insufficient and the leakage current cannotbe decreased. SUMMARY OF THE INVENTION

[0010] A purpose of the present invention is to provide a solidelectrolytic capacitor capable of decreasing a leakage current with afurther efficiency when compared with a capacitor aged under aninfluence of moisture absorption, and also to provide a method formanufacturing the capacitor.

[0011] A solid electrolytic capacitor of the present invention includesa capacitor element inside a packaging material. The capacitor elementincludes a valve action metal, an oxide film layer formed on a surfaceof the valve action metal, a solid electrolytic layer formed on theoxide film layer, and contains an organic compound having a boilingpoint of not lower than 150° C. and a melting point of not higher than150° C.

[0012] A method for manufacturing a solid electrolytic capacitor of thepresent invention includes a step of providing a capacitor element withan organic compound having a boiling point of not lower than 150° C. anda melting point of not higher than 150° C., and arranging the capacitorelement containing the organic compound inside a package.

[0013] Accordingly, because of the organic compound, a solidelectrolytic capacitor can be aged more efficiently when compared to aconventional method, and a solid electrolytic capacitor with lessleakage current can be provided easily.

BRIEF DESCRIPTION OF DRAWINGS

[0014]FIG. 1 is a flow diagram to illustrate a method for manufacturinga solid electrolytic capacitor according to the present invention FIG. 2is a cross-sectional view to illustrate a solid electrolytic capacitoraccording to the present invention FIG. 3 is a cross-sectional view toillustrate another solid electrolytic capacitor according to the presentinvention.

[0015]FIG. 4 is a cross-sectional view to illustrate still another solidelectrolytic capacitor according to the present invention.

[0016]FIG. 5 is a cross-sectional view to illustrate peeling in a solidelectrolytic film, which might occur as a result of repair of an oxidefilm.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The following explanation is about preferable embodiments in thepresent invention.

[0018] Since an organic compound included in a capacitor element has aboiling point of not lower than 150° C., the compound is difficult tovaporize even if it is heated during manufacture of the solidelectrolytic capacitor. In a process of manufacturing a solidelectrolytic capacitor, fixation of the capacitor element to anextraction terminal or formation of a cathodic layer often is carriedout with heating to at least about 150° C. Therefore, when the organiccompound has a boiling point of lower than 150° C., the organic compoundcannot be maintained securely after impregnation, and it may vaporize tocause failure in forming the cathodic layer etc. or in bonding to theextraction terminal. This vaporization will lower the electricproperties of the capacitor.

[0019] It is further preferable that the organic compound has a boilingpoint of not lower than 200° C., since the capacitor element will beheated at about 150° C. to 200° C. for thermosetting when a resin isformed to be a package through a transfer molding or dipping.

[0020] It is especially preferable that the organic compound has aboiling point of not lower than 250° C., since the capacitor is heatedat about 230° C. to 250° C. when a tip-type solid electrolytic capacitoris mounted on a substrate by soldering. However, the boiling point of anorganic compound used for a soldering capacitor is not always requiredto be equal to or higher than 250° C., since the organic compound willnot vaporize rapidly even if it has a boiling point of lower than 250°C., depending on the conditions relating to the mounting methods andheating period.

[0021] As the organic compound has a melting point of not higher than150° C., it will be present as a liquid or a solid that can be liquefiedquickly in part by Joule heat provided by leakage current at a defect onthe oxide film during a voltage application. Ions are eluted from asolid electrolytic layer through the liquid of the organic compound as asolvent (organic solvent), and thus, an electrolytic solution is formed.In this way, the capacitor element is provided with self-repairingcapacity. As a result, an oxide film damaged during a manufacturingprocess can be repaired easily with an aging voltage, and an oxide filmdamaged during a packaging step or during use can be self-repaired witha voltage during a use.

[0022] Preferably the organic compound is a solid at a room temperatureof 25° C. Such an organic compound will leak out of a package less, andit has an excellent retention. Preferably the organic compound has amelting point higher than 25° C. so that it keeps a solid state at aroom temperature. It is more preferable that the melting point is higherthan 40° C., since it can be present as a solid in an ordinarytemperature range (40° C. or lower) for using an electronic productincluding the solid electrolytic capacitor. When a resin is used for thepackage, it is preferable that the organic compound is prevented frompenetrating from the inside of the capacitor element and encroachinginto the resin. An organic compound having a melting point of higherthan 60° C. can be used preferably when the temperature range for use isset to be even higher.

[0023] When the organic solvent is provided with excessive ions, largecurrent may flow in the defects on the oxide film during a voltageapplication, and this may cause damage on the film. Therefore, theorganic compound is preferably made of a substance having ions that willnot substantially be dissociated, or a substance with a low dissociationconstant.

[0024] An organic compound for providing such an organic solvent can beselected from a group consisting of alcohols, phenols, esters, ethersand ketones, though there is no specific limitation. In thisdescription, technical terms regarding to the substances ranging fromalcohols to ketones are used in a wide sense. For example, the term‘phenol’ includes various phenol derivatives where hydrogen(s) of abenzene ring is substituted with a hydroxyl group. These compoundsgenerally provide organic solvents to make electrolytic solutions havingappropriate electroconductivity due to ions eluted from solidelectrolytes.

[0025] Organic acids also can be used for the organic compounds when thedissociation constant is not so high A preferable example of the organicacids includes a fatty acid. The organic acid preferably has adissociation constant of at least 4.5 when indicated by pKa at 25° C.,since appropriate dissociation will provide electroconductivity suitablefor repairing.

[0026] Another example of a preferable organic compound is an amine. Inthis specification, ‘amine’ includes aliphatic amines, aromatic amines,and also includes primary to tertiary amines. Amines have a function tocoordinate with hydrogen ions in the organic solvent and lower theconcentration of the hydrogen ions. Accordingly, damage of the oxidefilm, which is caused by a strong acid, can be controlled. In a casewhere aluminum is used for a valve action metal, the oxide film will bedamaged considerably when the hydrogen ion concentration is raised. Thisdamage can be controlled by using an amine.

[0027] When repairing an oxide film, hydrogen ions are reduced ingeneral due to a reaction accompanied by the repair, and hydrogen gas isgenerated. For actively controlling generation of hydrogen gas, it ispreferable that the capacitor element further contains a substancehaving a reduction potential higher than a hydrogen-generatingpotential, namely, an oxidizer that will be reduced more easily thanhydrogen. The substance is reduced prior to hydrogen so as to controlgeneration of a hydrogen gas.

[0028] Substances having reduction potentials higher than that inhydrogen generation include perchloric acids and their salts,permanganic acids and their salts, chromic acids and their salts,peroxodisuluric acids and their salts, and a compound including a nitrogroup. When a conductive polymer is used for a solid electrolyte, it ispreferable to select a substance that does not oxidize-decompose theconductive polymer. From this point of view, a compound including anitro group is the most preferable. Based on the above-mentioned reason,the substance preferably has a boiling point of not lower than 150° C.

[0029] Generated hydrogen gas increases the inner pressure of thecapacitor. The gas pressure is raised especially in an interface betweena solid electrolytic layer and a dielectric oxide film. When the innerpressure is raised excessively, the solid electrolytic layer may bepeeled off from the dielectric oxide film. When the solid electrolyticlayer is peeled off, a new problem will occur: capacitance of thecapacitor will be lowered In a conventional aging to repair an oxidefilm by using absorbed water, the generation of hydrogen gas due toreduction of hydrogen ions is inevitable. According to the preferableembodiment of the present invention, however, an oxide film can berepaired while controlling generation of hydrogen gas.

[0030] The above-mentioned substance that can control generation ofhydrogen gas is effective also in maintaining capacitance during are-formation process to provide a solid electrolytic capacitor. Sincere-formation is carried out in a solvent such as water or an alcoholhydrogen gas generated due to reduction of hydrogen ions may be aproblem similar to that in the above-mentioned process. It is preferablefor obtaining a stable leakage current property that re-formation iscarried out in each of several steps separately performed for forming asolid electrolytic layer. Though the re-formation steps can lower thecapacitance, peeling of the solid electrolytic layer can be controlledby including in the solid electrolyte a substance having a reductionpotential equal to or higher than the potential relating to hydrogengeneration.

[0031] Namely, a preferable embodiment of the present invention furtherincludes a step of repairing defects on an oxide film layer by applyinga dc voltage in a state that the solvent is contacted with either asolid electrolytic layer or a solid electrolyte composing a part of thesolid electrolytic layer before a capacitor element is arranged inside apackage, in which the solid electrolytic layer contains a substancehaving a reduction potential equal to or higher than the potentialrelating to hydrogen generation. An organic solvent such as water or analcohol, or a mixture thereof can be used as a solvent for theelectrolytic solution. A solid electrolytic layer can be formed byalternately repeating a step of forming a part of a solid electrolyticlayer and the above-described step of repairing defects on the oxidefilm layer.

[0032] Generation of hydrogen gas accompanying the repair of an oxidefilm will be explained below with reference to FIG. 5.

[0033] When voltage is applied to repair defective parts 110 of an oxidefilm 102, the following reaction (1) proceeds at a portion of thedefective part 110 in the vicinity of a valve action metal 101 (anodeside) while the following reaction (2) proceeds at a portion of thedefective parts 110 in the vicinity of the solid electrolytic layer 103(cathode side) (FIG. 5(A)). As a result, repaired parts 112 are providedto the oxide film by the reaction (1), while a peeling 111 of the solidelectrolytic layer may occur due to the pressure of hydrogen gasgenerated by the reaction (2) FIG. 5(B)). Though the following reactionformulas relate to a case where tantalum is used for the valve actionmetal similar reactions will occur if any other valve action metals areused.

2Ta+10OH—→Ta₂O₅+5H₂O+10e-  (1)

10H⁺+10e-→5H₂↑  (2)

[0034] For preventing the solid electrolytic layer from peeling off, asubstance added together with the organic compound is preferably asubstance not releasing a gas (i.e., not gasified) when being reduced,while it controls the reaction (2).

[0035] The organic compound can be a substance having per se a reductionpotential equal to or higher than the potential relating to hydrogengeneration. The substances include, for example, 3-nitroanisole (meltingpoint: 54° C., boiling point: 260° C.), which is a compound containing anitro group.

[0036] To provide self-repair capacity to a solid electrolytic capacitorby using an organic compound, consideration should be given to providingthe organic compound to the interior of a capacitor element and also tomaintaining the organic compound not to be lost during the manufacturingprocess. In a conventional method, various organic compounds are addedas polymerization accelerators when a conductive polymer is used for asolid electrolytic layer. However, since the conductive polymer layer iswashed after its formation process, hardly any of the added organiccompound remains after the polymerized conductive polymer is washed.Therefore, it is preferable that the organic compound is impregnatedafter a step of washing the solid electrolytic layer, or that a washingsolution in which the organic compound is difficult to dissolve shouldbe selected so that the organic compound will not be washed out even ifthe organic compound is impregnated before the washing step. As aresult, the capacitor element containing the organic compound can behoused in a case or covered with a packaging resin.

[0037] For an efficient repair, preferably the organic compound isimpregnated deep into the pores of the capacitor element. The followingmethod is especially preferable for deeply impregnating an organiccompound that is solid at a room temperature.

[0038] An example of the above-mentioned methods includes a step ofimpregnating a solution of an organic compound dissolved in a solventinto a capacitor element, and a step of applying heat for evaporatingthe solvent. A solvent preferably used here is an organic solvent havinga boiling point of not higher than 100° C., for example, lower alcoholssuch as ethanol and isopropyl alcohol.

[0039] In a second example regarding the above-mentioned method, anorganic compound is heated to generate a vapor to be impregnated into acapacitor element.

[0040] In a third example regarding the above-mentioned method, anorganic compound liquefied by heat is impregnated into a capacitorelement.

[0041] In a fourth example regarding the above-mentioned method, anorganic compound that is heated previously to lower its viscosity isimpregnated into a capacitor element.

[0042] The above-mentioned methods can be carried out at any of thestages between forming a solid electrolytic layer and arranging thecapacitor element inside a package.

[0043] In a fifth example regarding the above-mentioned method, anorganic compound is added to a solution for forming a solid electrolyticlayer in order to impregnate this organic compound into a capacitorelement.

[0044] A method can be selected from the above-mentioned onesappropriately corresponding to some factors such as variation of theorganic compounds. From a viewpoint of access to the deep parts of thepores, the solution of an organic compound dissolved in a solvent isimpregnated preferably before removing the organic compound byevaporation, or the solution is included preferably at a step of forminga solid electrolytic layer. From a viewpoint of raising the impregnationconcentration for an improved effect methods relating to evaporation andliquefaction can be used advantageously.

[0045] The thus impregnated organic compound is used to repair defectsof an oxide film. In other words, a dc voltage is applied to carry out afurther step of repairing defects of an oxide film that the liquefiedorganic compound contacts. When the organic compound is solid during theaging treatment, it is preferable that the organic compound is liquefiedby the heat generated due to the current concentrated on the defectsduring an application of the dc voltage, and also the defects of theoxide layer are repaired by the applied dc voltage.

[0046] Since re-formation can be carried out during a step of forming asolid electrolytic layer, influence of washing can be ignored. Asubstance having a reduction potential equal to or higher than thepotential relating to hydrogen generation can be included in the solidelectrolytic layer by, for example, adding the same substance to asolution prepared for forming the solid electrolytic layer.Alternatively, this substance can be included in a solid electrolyticlayer by contacting a solution containing this substance with either asolid electrolytic layer or a solid electrolyte composing a part of thesolid electrolytic layer.

[0047] Preferably, the substance having a reduction potential equal toor higher than the potential relating to hydrogen generation iscontained in the solid electrolytic layer within a range from 50 ppm to10wt %. If the concentration is extremely low, a sufficient effect maynot be obtained in lowering the capacitance. If the concentration isextremely high, electroconductivity of the conductive polymer may belowered. Since the solid electrolytic layer is washed afterre-formation, the concentration value measured for a solid electrolyticcapacitor as a final product can be lower than the same value measuredduring the re-formation.

[0048] In the following, solid electrolytic capacitors and methods ofmanufacturing the same according to the present invention will beexplained with a reference to FIGS. 2-4.

[0049] In a solid electrolytic capacitor shown in FIG. 2, a capacitorelement is covered with a packaging resin 9. Regarding this solidelectrolytic capacitor, the capacitor element is composed of an anode 1made of a valve action metal, a dielectric oxide film 2 formed on thesurface of the valve action metal, a solid electrolytic layer 3 formedon the dielectric oxide film, and a cathodic layer 4 formed on the solidelectrolytic layer.

[0050] The capacitor element is covered as a whole with a packagingresin 9, excepting where a cathodic extraction terminal 7 and an anodicextraction terminal 8 are extracted through the packaging resin 9outward to secure its electroconductivity The anodic extraction terminal8 is connected with the anode 1 via an anodic lead 5. The cathodicextraction terminal 7 is connected with the cathodic layer 4 via aconductive adhesive 6 or the like.

[0051] A solid electrolytic capacitor to which the present invention isapplicable will not be limited to the embodiment shown in FIG. 2.Alternatively, an anodic extraction terminal can be omitted. In thiscase, a pair of external terminals 10 can be arranged to be respectivelyconnected to an anodic lead 5 and to a cathodic extraction terminal 7that are exposed to the surface of the package 9 as shown in FIG. 3.Alternatively, the cathodic extraction terminal also can be omitted, anda cathodic foil 11 that is stuck to a cathodic layer 4 with a conductiveadhesive 6 etc. is exposed to the surface of the package 9, and a pairof external terminals 10 are connected to this cathodic foil 11 and toan anodic lead 5 respectively. See FIG. 4. In such a configuration,formation of the cathodic layer 4 and the conductive adhesive 6 can beomitted. Or, similar to a conventional electrolytic capacitor of anelectrolytic solution type, a solid electrolyte can be filled instead ofan electrolytic solution in a roll of a laminate composed of an anodicfoil, a cathodic foil and a separator, though this is omitted from thedrawings. In this case, respective leads attached to the anodic foil andthe cathodic foil are extracted from the package to make terminals.

[0052] The respective members are further explained in the following.

[0053] The anode 1 is made of a valve action metal. Preferably,aluminum, tantalum or niobium can be used for the valve action metal.Though omitted from the drawings, the anode is a porous compact providedwith numbers of micro-holes or pores communicating with the outersurface.

[0054] When aluminum is used for the anode, an aluminum foil can beroughened by etching or the like to be provided with numbers ofmicropores. When tantalum or niobium is used, a porous compact can beprepared by press-molding a powder of the valve action metal beforesintering. Or the valve action metal powder can be applied to form asheet and sintered to provide a porous compact. These porous compactfoils can be rolled or laminated for use.

[0055] The dielectric oxide film layer 2 can be formed by anodizing thesurface of a porous compact of a valve action metal. Though this also isomitted from the drawings, the dielectric oxide film layer is formed ingeneral on the entire surface of the valve action metal and also on thesurface of the micro-pores provided to the porous compact, excepting apart of the anodic lead 5 for connecting with the anodic extractionterminal.

[0056] The solid electrolytic layer 3 can be formed from manganesedioxide or a conductive polymer material. This layer is formed alsoinside the micro-holes of the porous compact, though this also isomitted from the drawings. Conductive polymers such as polypyrrole,polyaniline, and polythiophene can be used preferably for the solidelectrolyte, but there is no specific limitation.

[0057] The cathodic layer 4 can be made of a carbon layer, a silverlayer or the like, for collecting electric capacity extracted by thesolid electrolytic layer. The cathodic layer is formed on the foilsurface when the valve action metal porous compact as an anode iscomposed of a foil However, when the porous compact is a roll or alaminate of foils, the cathodic layer can be formed on the outer surfaceof the entire porous compact. When the porous compact is composed of asintered powder, the cathodic layer will be formed on the outer surface.The cathodic layer is not an essential element. Depending on thestructure and materials, the solid electrolytic layer 3 can be bondeddirectly to the cathodic extraction terminal 7.

[0058] The cathodic extraction terminal 7 is bonded to the cathodiclayer 4 in general with a conductive adhesive layer 6 like asilver-based adhesive. When the cathodic extraction terminal 7 is bondeddirectly to the solid electrolytic layer 3, the conductive adhesivelayer 6 also can be omitted.

[0059] The anodic extraction terminal 8 is bonded to the anodic lead 5inserted into the anode by welding or the like.

[0060] The package 9 is formed to cover the entire element exceptingparts where the cathodic extraction terminal 7 and the anodic extractionterminal 8 pass through. The package can be a case of ceramic, resin ormetal. In the embodiment shown in the drawings, a packaging resin isused. Preferably the packaging resin is formed by molding or dipping.The resin can be, for example, an epoxy-based resin.

[0061]FIG. 1 is a flow diagram to illustrate an example of a method tomanufacture a solid electrolytic capacitor according to the presentinvention

[0062] First, an anode is formed by etching a valve action metal foil orby forming a sintered compact of a valve action metal powder. Next, adielectric oxide film is formed on the surface of the anode, and a solidelectrolytic layer is formed on the oxide film. Subsequently, a cathodiclayer is formed if necessary These steps can be carried out inaccordance with a conventional technique.

[0063] In the steps illustrated in FIG. 1, an organic compound isimpregnated into a capacitor element by the above-mentioned method afterformation of a cathodic layer. However, impregnation of the organiccompound can be carried out at any stage between formation of the solidelectrolytic layer and either formation or sealing of the package. Or anorganic compound can be impregnated by adding the organic compound to asolution used for forming the solid electrolytic layer. As mentionedabove, a substance having a potential equal to or higher than thepotential relating to hydrogen generation can be added at the same timeto this solution.

[0064] The substance having a reduction potential equal to or higherthan the potential relating to hydrogen generation can be included inthe solid electrolytic layer by contacting a solution including thissubstance with either a solid electrolytic layer or a solid electrolytecomposing a part of the solid electrolytic layer. As mentioned above,this substance will control peeling of the solid electrolytic layerduring the re-formation.

[0065] Bonding to the cathodic extraction lead and the anodic extractionlead is carried out in a subsequent assembling step. A capacitor elementis finally arranged inside the package by inserting and sealing in thepackaging case, or as a result of a formation of a packaging resin. Ifnecessary, the terminal parts that are not covered with the package willbe folded in a certain direction.

[0066] Thus obtained solid electrolytic capacitor includes a capacitorelement having an organic compound inside thereof. The oxide film hasself-repairing capacity since ions will be eluted from the solidelectrolyte into this organic compound, or specifically, into an organicsolvent of a liquefied organic compound existing inside of the solidelectrolyte and also in the interface between the dielectric oxide filmand the solid electrolyte. A solid electrolytic capacitor with lessleakage current can be provided efficiently due to this self-repairingcapacity.

[0067] The organic compound is not required to be liquefied as a whole.It should be liquefied at a part where leakage current flows by Jouleheat generated due to the leakage current so as to serve as a solvent.

[0068] When a conductive polymer is used as a solid electrolyte, theorganic compound impregnated into the solid electrolytic layer can draindopant in the conductive polymer out (de-doping) easily at defectiveparts in the dielectric oxide film. The resistance value of theconductive polymer will be raised when the de-doping occurs. Leakagecurrent also can be decreased by such a secondary effect.

[0069] The present invention will be further described below byreferring to some examples, though the examples are not intended torestrict the present invention.

COMPARATIVE EXAMPLE

[0070] First, for a comparison, a solid electrolytic capacitor wasmanufactured without impregnating an organic compound.

[0071] A tantalum powder was molded with a lead and sintered to form avalve action metal porous compact of 1.4 mm×3.0 mm×3.8 mm. Next, thewhole surface of the porous compact including pores surface was anodizedexcepting lead tips with a formation voltage of 20V in an aqueoussolution of phosphoric acid so as to form a dielectric oxide film layer.Subsequently, a solid electrolytic layer of polypyrrole was formed by achemical oxidative polymerization of a pyrrole monomer on the surface ofthe dielectric oxide film layer including the inner surface of thepores.

[0072] A carbon layer and a silver layer were laminated on the solidelectrolytic layer applied to the outer surface of the porous compact.These layers serve as cathodic layers. Then, a cathodic extractionterminal is adhered with a silver-based adhesive (a conductive adhesive)to the cathodic layer, while an anodic extraction terminal is bonded bywelding to a lead of the porous compact of the valve action metal as ananode. Further, a package was formed by transfer-molding of anepoxy-based resin. Exposed portions of the cathodic extraction terminaland the anodic extraction terminals were folded so that a solidelectrolytic capacitor having a cross section similar to that of FIG. 2was obtained.

EXAMPLE 1

[0073] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an alcohol was impregnated into acapacitor element in a stage where a cathodic layer was formed. Thealcohol was glycerol having a melting point of 17° C. and a boilingpoint of 290° C. In the impregnation, the capacitor element was dippedin a solution of isopropyl alcohol in which 20 weight % of glycerol wasdissolved After being taken out from the solution, the element washeated at 120° C. to evaporate the isopropyl alcohol.

Example 2

[0074] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an alcohol was impregnated into acapacitor element in a stage where a cathodic layer was formed. Thealcohol was glycerol having a melting point of 17° C. and a boilingpoint of 290° C. In the impregnation, two small containers includingrespectively a capacitor element and glycerol were disposed in a sealedcontainer. The glycerol was heated at 100° C. to generate a vapor, andthe capacitor element was exposed to the vapor.

Example 3

[0075] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an alcohol was impregnated into acapacitor element in a stage where a cathodic layer was formed. Thealcohol was stearyl alcohol having a melting point of 59° C. and aboiling point of 210° C. In the impregnation, the capacitor element wasdipped in a solution of ethanol in which 3 weight % of stearyl alcoholwas dissolved. After being taken out from the solution, the element washeated at 100° C. to evaporate the ethanol.

Example 4

[0076] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an alcohol was impregnated into acapacitor element in a state where a conductive polymer layer wasformed. The alcohol was stearyl alcohol having a melting point of 59° C.and a boiling point of 210° C. In the impregnation, the capacitorelement was dipped in a solution of ethanol in which 3 weight % ofstearyl alcohol was dissolved. After being taken out from the solution,the element was heated at 100° C. to evaporate the ethanol.

Example 5

[0077] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that a phenol (a phenol derivative) wasimpregnated into a capacitor element in a stage where a cathodic layerwas formed. The phenol was 2,3-xylenol having a melting point of 73° C.and a boiling point of 218° C. In the impregnation, the capacitorelement was dipped in a solution of ethanol in which 10 weight % ofxylenol was dissolved. After being taken out from the solution, theelement was heated at 100° C. to evaporate the ethanol.

Example 6

[0078] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that a phenol (a phenol derivative) wasimpregnated during a step of forming a conductive polymer layer. Thephenol was 2,3-xylenol having a melting point of 73° C. and a boilingpoint of 218° C. In the impregnation, a chemical oxidativepolymerization was carried out by using a solution in which xylenol wasdissolved. Specifically, a conductive polymer was formed by a chemicaloxidative polymerization in which a pyrrole monomer solution (a mixtureof water/ethanol in which pyrrole is dissolved) including 10 weight % ofxylenol and a solution of an oxidant (a mixture of water/ethanol inwhich iron sulfide (III) is dissolved) including 10 weight % of xylenolwere prepared and the capacitor was dipped alternately in these twosolutions. In a washing step following the formation of the conductivepolymer layer, water was used for the washing solution since solubilityof xylenol thereto is low. As a result, xylenol was included in thecapacitor element at the same time the conductive polymer layer wasformed.

Example 7

[0079] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an ester was impregnated into acapacitor element in a stage where a cathodic layer was formed. Theester was butyl benzoate having a melting point of −22° C. and a boilingpoint of 250° C. In the impregnation, a solution with a low viscositywas prepared by heating the butyl benzoate at 100° C., and a capacitorelement was dipped in this solution.

Example 8

[0080] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an ether was impregnated into acapacitor element in a stage where a solid electrolytic layer wasformed. The ether was diphenyl ether having a melting point of 28° C.and a boiling point of 259° C. In the impregnation, the capacitorelement was dipped in a solution of ethanol in which 5 weight % ofdiphenyl ether was dissolved. After being taken out from the solution,the element was heated at 100° C. to evaporate the ethanol.

Example 9

[0081] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that a ketone was impregnated into acapacitor element in a stage where a solid electrolytic layer wasformed. The ketone was phorone having a melting point of 28° C. and aboiling point of 199° C. In the impregnation, the capacitor element wasdipped in a solution of ethanol in which 5 weight % of phorone wasdissolved. After being taken out from the solution, the element washeated at 100° C. to evaporate the ethanol.

Example 10

[0082] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that a fatty acid was impregnated into acapacitor element in a stage where a cathodic layer was formed. Thefatty acid was stearic acid (pKa>4.6) having a melting point of 71° C.and a boiling point of 360° C. In the impregnation, the capacitorelement was dipped in a solution obtained by melting the stearic acidwith heat at 100° C.

Example 11

[0083] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an amine was impregnated into acapacitor element in a stage where a cathodic layer was formed. Theamine was triethanolamine having a melting point of 21° C. and a boilingpoint of 360° C. In the impregnation, the capacitor element was dippedin a solution of ethanol in which 5 weight % of triethanolamine wasdissolved After being taken out from the solution, the element washeated at 100° C. to evaporate the ethanol.

Example 12

[0084] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that an amine was impregnated into acapacitor element in a stage where a cathodic layer was formed. Theamine was diphenylamine having a melting point of 53° C. and a boilingpoint of 310° C. In the impregnation, the capacitor element was dippedin a solution obtained by heating the diphenylamine at 100° C.

Example 13

[0085] A solid electrolytic capacitor was obtained in the same way asthe Example 1 except that a nitro group containing compound wasimpregnated into a capacitor element in a stage where a solidelectrolytic layer was formed. The nitro group containing compound was4-nitrophthalic acid having a melting point of 165° C. This capacitorelement contains glycerol and nitrophthalic acid. For impregnatingnitrophthalic acid, a capacitor element was dipped in a solution as amixture of water/ethanol including 2 weight % of 4-nitrophthalic acidAfter being taken out from the solution, the element was heated at 100°C. to evaporate water/ethanol.

Example 14

[0086] A solid electrolytic capacitor was obtained in the same way asthe Example 1 except that a nitro group containing compound wasimpregnated into a capacitor element during a step of forming aconductive polymer layer. The nitro group containing compound was3-nitroansole having a melting point of 54° C. and a boiling point of260° C. This capacitor element contains glycerol and nitroanisole. Forimpregnating nitroanisole, a chemical oxidative polymerization wascarried out using a solution in which nitroanisole was dissolved.Specifically, a conductive polymer layer of polypyrrole containingnitroanisole was formed by a chemical oxidative polymerization in whicha monomer solution including 1 weight % of 3-nitroanisole and a solutionof an oxidant (a mixture of water/ethanol in which iron sulfide (III) isdissolved) including 1 weight % of 3-nitroanisole were prepared and thecapacitor was dipped alternately in these two solutions. In a washingstep following formation of the conductive polymer layer, water was usedfor the washing solution since the solubility of nitroanisole thereto islow.

Example 15

[0087] A solid electrolytic capacitor was obtained in the same way asthe Comparative Example except that a nitro group containing compoundwas impregnated into a capacitor element in a stage where a solidelectrolytic layer was formed. The nitro group containing compound was3-nitroanisole having a melting point of 54° C. and a boiling point of260° C. In the impregnation, the capacitor element was dipped in asolution of ethanol in which 3 weight % of 3-nitroansole was dissolved.After being taken out from the solution, the element was heated at 100°C. to evaporate the ethanol. A solid electrolytic capacitor rated at6.3V and with a standard value of 150 μF was obtained in any of theabove-mentioned Comparative Example and Examples 1-15.

[0088] These solid electrolytic capacitors were aged for one hour byapplying a voltage of 10V at a room temperature. Respectively 100capacitors were aged for the Examples and Comparative Example.

[0089] For the capacitors in the Comparative Example, the leakagecurrent was as large as 20 μA to 100 μA and the values were not loweredto an applicable range. On the other hand, the leakage current for thecapacitors in the Examples was lowered to 5 μA or less as a result ofaging for several minutes, and the leakage current was controlledsuccessfully to a practical level.

[0090] To control the leakage current of a capacitor in the ComparativeExample within a practical range, aging should be carried out by amoisture absorption at a temperature of 85° C. and at a relativehumidity of 85%, which was immediately followed by application ofvoltage 10V at the above-mentioned temperature. Though this method couldcontrol leakage current to be 5 μA or less, the time for the aging,including times for moisture absorption, stretched over a period oftenor more hours. Since such a capacitor includes amounts of water, thepackage had cracks due to the water vaporizing rapidly by the heat at asolder mounting. To prevent this problem, a drying step should becarried out after the aging. As a result, the entire aging process wasfurther prolonged. After a drying step for 40 hours at 120° C., theleakage current was about 10 μA on average. The leakage current wasincreased after the drying step. An applicable explanation for this isthat the oxide film was damaged again because of thermal stress appliedduring the drying step.

[0091] One hundred aged capacitors were prepared for every Example (forthe Comparative Example, capacitors were aged and re-dried after amoisture absorption). The capacitors were soldermounted to substrates.In a subsequent acceleration reliability test, a voltage 1.2 times ofthe rated voltage was applied for 500 hours under a condition of 120° C.In an evaluation that was carried out after the test for each capacitor,the leakage current for seven capacitors of the Comparative Example was30 μA or higher, while the leakage current did not exceed 10 μA for thecapacitors of the Examples.

[0092] The capacitance of the capacitors in the respective Examples was135 μF to 165 μF after the aging, and these values did not differremarkably from the standard value (150 μF). For capacitors in Examples1-12, capacitance values ranged from 135 μF to 155 μF, which weresomewhat low. For capacitors in the Examples 13, 14 where nitro groupcontaining compounds were added together and for capacitors in theExample 15 where a nitro group containing compound was included as anorganic compound, capacitance as high as 150 μF to 165 μF was kept.

[0093] As mentioned above, the leakage current was lowered efficientlyfor the capacitors in the respective Examples. Furthermore, when acompound having a reduction potential equal to or higher than ahydrogen-generating potential, e.g., a nitro group containing compoundis added, the obtained capacitor will have a capacitance that is loweredless even if the capacitor is aged to lower the leakage current

[0094] Though these examples relate to molded products, similar effectsare obtainable for dipped products. The leakage current would beincreased for molded or dipped products especially due to stress causedby resin-setting at forming a package. Therefore, the present inventionwill be used preferably for these products.

[0095] For a product inserted in a case as a package, lowering of theleakage current is preferable. The present invention will be preferableespecially, when a capacitor element is completely sealed in a case ofceramic, resin, metal or the like, since repairing under an influence ofmoisture absorption is difficult for such a capacitor.

[0096] Though these examples relate to tantalum solid electrolyticcapacitors, similar effects can be obtained for capacitors having anodesof niobium or aluminum. It should be noted that when an amine isincluded in an aluminum electrolytic capacitor, the capacitor had lessleakage current when compared to a capacitor in which any other organiccompounds were included. In a comparison of aluminum electrolyticcapacitors manufactured under the same condition, the leakage currentfor capacitors having impregnated glycerol was 10 μA on average whilethe leakage current for capacitors having impregnated triethanolaminewas 5 μA or less.

[0097] The invention may be embodied in other specific forms withoutdeparting from the spirit or essential characteristics thereof theembodiments disclosed in this application are to be considered in allrespects as illustrative and not restrictive, the scope of the inventionbeing indicated by the appended claims rather than by the foregoingdescription, all changes that come within the meaning and range ofequivalency of the claims are intended to be embraced therein.

1-13. (Cancelled)
 14. A method for manufacturing a solid electrolyticcapacitor comprising a package and a capacitor element inside thepackage, the capacitor element comprising a valve action metal, an oxidefilm layer formed on the surface of the valve action metal, and a solidelectrolytic layer formed on the oxide film layer, the methodcomprising, making the capacitor element containing an organic compoundhaving a boiling point of not lower than 150° C. and a melting point ofnot higher than 150° C., and arranging the capacitor element containingthe organic compound inside the package, wherein the organic compounddoes not substantially dissociate.
 15. The manufacturing methodaccording to claim 14, wherein the organic compound is included in thecapacitor element by impregnating a solution prepared by dissolving theorganic compound in a solvent into the capacitor element and evaporatingthe solvent by heat.
 16. The manufacturing method according to claim 14,wherein the organic compound is included in the capacitor element byimpregnating a vapor generated by heating the organic compound into thecapacitor element.
 17. The manufacturing method according to claim 14,wherein the organic compound is included in the capacitor element byimpregnating the organic compound that is liquefied by heating into thecapacitor element.
 18. The manufacturing method according to claim 14,wherein the organic compound is included in the capacitor element byimpregnating the organic compound into the capacitor element afterlowering the viscosity of the organic compound by heating.
 19. Themanufacturing method according to claim 14, wherein the organic compoundis included in the capacitor element by adding the organic compound to asolution for forming the solid electrolytic layer.
 20. The manufacturingmethod according to claim 14, wherein the capacitor element is made tofurther contain a substance having a reduction potential that is equalto or higher than a hydrogen-generating potential.
 21. The manufacturingmethod according to claim 14, further comprising applying a dc voltageso as to repair a defect of the oxide film.
 22. The manufacturing methodaccording to claim 21, wherein a defect of the oxide film layer isrepaired by applying a dc voltage while liquefying the organic compoundby heat generated due to the applied dc voltage.
 23. The manufacturingmethod according to claim 14, wherein the organic compound is at leastone selected from the group consisting of alcohol, ester, ether, andketone.
 24. A method for manufacturing a solid electrolytic capacitorcomprising a package and a capacitor element inside the package, thecapacitor element comprising a valve action metal, an oxide film layerformed on the surface of the valve action metal, and a solidelectrolytic layer formed on the oxide film layer, the methodcomprising, making the capacitor element containing an organic compoundhaving a boiling point of not lower than 150° C. and a melting point ofnot higher than 150° C., and arranging the capacitor element containingthe organic compound inside the package, wherein the organic compound isat least one selected from the group consisting of alcohol, ester,ether, and ketone.
 25. The manufacturing method according to claim 24,wherein the organic compound is included in the capacitor element byimpregnating a solution prepared by dissolving the organic compound in asolvent into the capacitor element and evaporating the solvent by heat.26. The manufacturing method according to claim 24, wherein the organiccompound is included in the capacitor element by impregnating a vaporgenerated by heating the organic compound into the capacitor element.27. The manufacturing method according to claim 24, wherein the organiccompound is included in the capacitor element by impregnating theorganic compound that is liquefied by heating into the capacitorelement.
 28. The manufacturing method according to claim 24, wherein theorganic compound is included in the capacitor element by impregnatingthe organic compound into the capacitor element after lowering theviscosity of the organic compound by heating.
 29. The manufacturingmethod according to claim 24, wherein the organic compound is includedin the capacitor element by adding the organic compound to a solutionfor forming the solid electrolytic layer.
 30. The manufacturing methodaccording to claim 24, wherein the capacitor element is made to furthercontain a substance having a reduction potential that is equal to orhigher than a hydrogen-generating potential.
 31. The manufacturingmethod according to claim 24, further comprising applying a dc voltageso as to repair a defect of the oxide film layer.
 32. The manufacturingmethod according to claim 31, wherein a defect of the oxide film layeris repaired by applying a dc voltage while liquefying the organiccompound by heat generated due to the applied dc voltage.